properly. The delivery valve holder must be assembled with
a twelve point wrench, and retorqued to 0-80 ft-lbs. The cap
nut must be retorqued to 55-60 ft-lbs.
7-19. CYLINDER BLOCK.
a. Clean and Inspect.
(1) Steam clean cylinder block to remove deposits
of oil and dirt. Immerse block in solvent tank to clean out
(2) Inspect top surface of cylinder block, the surface
that mates with the cylinder head, for warping. Check both
across cylinders and in line with cylinder.
(3) Use magnetic particle method to check the
cylinder block for cracks. Replace block if cracked.
(4) Cylinder walls should be free of scratches, pit-
ting and scuffing. Check each cylinder with an inside reading
micrometer for out-of round and wear. See Table 1-2 for
b. Overhaul and Rebuild. Always de-glaze cylinder
walls. If necessary, hone or rebore the cylinder to fit the next
available oversize piston. Pistons and rings are available in
0.005, 0.010, 0.020, 0.030 and 0.040 inch oversize. If cylin-
ders do not need refinishing, remove any existing ridges
from top of wall with a fine stone.
Install. If the cylinder block requires replacement a
new set of injection pump shims must be used and the
injection pump must be re-timed. The shims are supplied
with the replacement cylinder block. Refer to paragraph
7-18 a. (3) for calculation of the shim thickness.
7-20. FUEL INJECTOR.
All injector openings and injector nozzles must
be capped when the injector is removed from the
(1) Remove fuel lines (3 and 7, figure 7-1) at fuel
(2) Remove screws (1, figure 7-45), washers (2) and
retaining flanges (3).
(3) Remove fuel injector (4), gasket (5), aapter (6),
gasket (7), heat shield (8) and gasket (9). Separate injector
from other components.
Do not attempt to disassemble nozzles or adjust
nozzle pressure without the proper test equip-
ment. A nozzle pressure tester is essential to do
Do not allow nozzle to spray against skin. Fuel
under nozzle pressure can penetrate flesh and
cause a serious infection.
b. Test. Install nozzle to be tested on a static fuel nozzle
testing fixture. Increase fuel pressure until nozzle opens.
Opening pressure should be 1950 ± 25 psi for a new nozzle
or 1750 ± 25 psi for a used nozzle (200 hours or more). If
nozzle opening pressure is lower, adjust to 1950 psi for a new
nozzle or 1750 psi for a used nozzle (see adjustment proce-
(1) Remove pipe plug (1, figure 7-46).
(2) Loosen (do not remove) cover (2).
(3) Install injector nozzle on a static fuel nozzle
(4) Insert a 5/32 inch hex socket key through hole in
(5) Adjust opening pressure with hex key to correct
pressure ( 1750 psi for a used injector, 1950 psi for a new
(6) Tighten cover (2), and recheck opening pressure.
When removing and disassembling fuel injec-
tors, separate and label components of each
injector. Never interchange components of
Never clamp injector in a vise without soft jaws.
(1) Secure injector in a holding fixture and remove
nozzle cap nut (12, figure 7-46) and nozzle (9).
Do not remove nozzle unless replacement is
(2) Install nozzle cap nut (12) loosely to protect
lapped surfaces of injector body.
e. Clean. Clean injectors in a clean room on a
clean work bench. Provide a van of clean diesel fuel and
a supply of lint-free wiping cloths. Never use hard or
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